SAIL Roadmap for Low

Carbon Future
 Recap
Effects of Climate Change, Global Response &
Pathways

2
A 3C World

The world is on a path to warm around 3oC above pre-

industrial levels by 2100 under policies and
commitments currently in place. This is a far cry from
the 1.5oC and 2oC targets enshrined in the Paris
agreements.

3
Indian Response to Paris Agreement

▷ NDC target - To reduce the emissions intensity of its GDP by 33 to 35% by

2030 from 2005 level.

▷ Ministry of Steel set target for reducing GHG emissions in Iron & Steel sector
by 2030:

 2.2 -2.4 T/TCS in BF-BOF route, and

 2.6- 2.7 T/TCS in DRI- EAF route

▷ SAIL set target for reducing CO2 emissions to 2.3 T/TCS by 2030:

4
 Panchamrit – India’s commitments at COP26

ENHANCED AMBITION

• Enhance non-fossil energy capacity to 500 GW

• Reduce economy's carbon intensity down by 45%
2030
• 50% of energy requirement through renewable energy
• Reduce 1 billion tonnes of carbon emissions

2070 • Achieve Net Zero Emissions

Mitigation and Adaptation as Low Carbon Pathways

AVOIDING & REDUCING GHG EMISSION

MITIGATION

CAPTURING &SEQUESTERING EXCESS GHG

FROM ATMOSPHERE
CLIMATE CHANGE

ALTERING OUR BEHAVIOUR AND SYSTEM TO

ADAPTATION BEST ADAPT THE CHANGED CLIMATE
CONDITIONS

6
 GHG Emissions
Iron & Steel Industry Perspective

7
CO2 footprint of Global Steel Industry
▷ ~3.5 Giga tonne of CO2 (Gt CO2)
emissions in 2019.
▷ 2.6 Gt CO2 was Scope-1 and 0.9
GT CO2 was Scope-2 emissions.
▷ BF-BOF steel production emitted
around 3 Gt CO2.
▷ Steel industry accounts for 7% of
total global GHG emissions.

Source: https://www.globalefficiencyintel.com/new-blog/2021/global-steel-industrys-ghg-emissions
8
 Projections - National Steel Demand and Corresponding increase
in GHG Emissions

Image courtesy: The Energy and Resources Institute (TERI) - Towards a Low Carbon Steel Sector Overview of the Changing Market,
Technology, and Policy Context for Indian Steel 9
 CO2 Emissions from BF Iron Making constitutes major part of entire
Steelmaking Process

Image courtesy: Nippon Steel Corporation 10

 CO2 Emission & Energy Consumption - SAIL vis-à-vis Peer Steel
Manufacturers
8.00 5.00

6.78 6.61
6.52 6.40 6.48 6.48 6.37 6.54
Sp. Energy Consumption (Gcal/tcs)

6.19 6.25 6.24 4.00

6.00 5.61 5.76

Sp. CO2 Emission (t/tcs)

2.84
2.69
2.68

3.00

2.59
2.55
2.54

2.52

2.52

2.49
2.44

2.44

2.33
2.29
4.00

2.00

2.00
1.00

0.00 0.00
BSP DSP RSP BSL ISP SAIL RINL TSJ TSK Tata Steel JSW JSPL Tata-BSL

Sp. Energy Consumption (Gcal/tcs) Sp. CO2 Emission (t/tcs)

Low Carbon Future for SAIL
3-Phase Decarbonisation Roadmap

12
 3-phase Roadmap for Carbon Neutrality
Decarbonisation Phase-1 Decarbonisation Phase-2 Deep-Decarbonisation
(Current MODEX) Phase-3
(Vision 2030) (Beyond Vision 2030)

Decarbonisation process took Carbon Abatement through: Gradual shift to alternate steel
momentum during modernisation making.
Implementing Energy Efficient
and Expansion (MODEX)
Technologies in Vision 2030 plan. Adoption & propagation of
programme started in 2008.
Hydrogen Steelmaking.
Enhancing energy efficiency of existing
Host of energy saving clean
units through retrofitting/revamping. Availing full renewable energy
technologies introduced in process.
generation potential of SAIL
Phasing out hard to abate old energy
Significant (`18%) improvement in
intensive units. Production of advanced high
carbon foot print.
strength steel for societal
Raw Material quality improvement
Further improvement with ramping up transformation
of capacity of MODEX facilities Study of development and
Wide coverage of CCUS across
acclimatization of break through iron
SAIL.
making & carbon capture facilities
13
Plant-wise performance last 10 years

Note: Graphical representations of IISCO

Steel Plant are for post-modernisation
period

14
SAIL Performance last 10 years and impact of energy efficient
technologies of MODEX
7 2.9

6.86

6.68
6.8
2.8

6.59
2.81

6.6
6.52

6.51

6.49

6.48
6.6

6.47
6.5
2.75
2.7

2.69
6.4

2.65
2.6

2.61
6.2

2.6

2.57
2.56

2.55
2.54
2.5
6

5.8 2.4
11-12 12-13 13-14 14-15 15-16 16-17 17-18 18-19 19-20 20-21

Sp. Energy Consumption (Gcal/tcs) Sp. CO2 Emission (t/tcs)

Particular Unit 2005-06 2020-21 % change

Specific Energy Consumption GCal/tcs 7.24 6.48 10.50% improvement

Specific CO2 Emissions T/tcs 3.10 2.55 17.74% improvement 15
 Phase-1 Decarbonisation
MODEX paves way for CO2 Emission Reductions

16
Strategy adopted during Phase-1 Decarbonisation in SAIL

 Through Technology Deployment

 Improvement in Quality of Raw Materials

 Improvement in Fuel rate

 Enhancing material efficiency (4R’s principle)

 Promotion of Renewable Energy

 Afforestation for creation of Carbon Sink

17
 CO2 Emission Reduction Potential Created during MODEX

GHG Emission Reduction potential

Major technologies Implemented
(Tonnes per year)
7m tall Coke Oven Battery with Coke Plant Automation and Process Control System and
3,54,000
CDCP at BSP, RSP & ISP

Top Pressure Recovery Turbine based large volume (>4000 m3) BFs at BSP, RSP & ISP 3,42,345

BF Stove Waste heat recovery at BSP, RSP, BSL & ISP 81,019
Coal Dust Injection in Blast Furnaces 12,12,527
Sinter cooler Waste heat recovery at BSP and BSL 87,050
BOF gas Recovery with gas holder at BSP, BSL and ISP 6,04,800
Utilisation of BF gas at Plant, in downstream facilities. 3,54,000
Energy efficient twin-shaft kiln at BSP, RSP and ISP 50000

Modification of burners of lime kilns of at BSP 50,000

Other small schemes to contribute for CO2 Emission Reduction 3,00,000

Estimated CO2 Emission Reduction Potential 34,35,741 18

 Indicative Cost of major Energy Efficient Technologies

Unit CO2 reduction technology Estimated Cost in (INR

Crs.)

Blast Furnace Waste Heat Recovery from BF Stoves 15.00

Coal Dust Injection 126.00
BF Top-gas pressure Recovery Turbine 98.00
Coke Ovens Coke Dry Cooling Plant 287.00
Sinter Plant WHR from Sinter Coolers 15.00

Indicative cost provided based on the costs during modernisation moderated with WPI 2021

19
 Other Notable Energy Efficiency Initiatives
▷ Installation of energy-efficient gas burners and replacement of old & worn out air
preheater blocks in Boiler#5 to improve its performance, BSP
▷ Fuel enrichment in the BF#4 Stove to increase Hot Blast Temperature (HBT)
through CO gas booster, DSP
▷ Repair of recuperators of Reheating Furnace (RHF) at BSL
▷ Walking-beam type re-heating furnaces at Rolling Mills
▷ Introduction of Variable Voltage Variable Frequency (VVVF) drives in plant
machineries etc.
▷ Gradual switching over to energy-efficient LED lights from conventional lighting
systems at plants and units.
20
Carbon sink of >21.5 million trees created
▷ 34.2% of land area covered with greenery.
▷ SAIL has a plan for planation of 5 lakhs trees per year.
Cumulative Plantation since Inception (numbers in Lakhs)
210.42 212.14
205.97 215.26
201.54

193.26

16-17 17-18 18-19 19-20 20-21 21-22 (Upto

Nov'21) 21
 “Potential of Reducing CO2 Footprint from
Existing Processes as well as MODEX Units is
yet to be fully attained”

22
Phase-2 Decarbonisation
Way forward to reach 2.30 T/tcs

23
 Improvement in Coke Rate and CDI injection
 Major CO2 emissions related to coal
Best Achieved in last 5 years 2021-22 (H1) carbonization and coke use.
Plant Coke Correspo Corresp Coke CDI Observation:
CDI
Rate nding onding Rate (kg/
year (kg/thm) year
(kg/thm) (kg/thm) thm)  Low coke rate corresponds with high
BSP 447 2020-21 76 2020-21 450 69 CDI rate.
DSP 459 2018-19 57 2018-19 465 48
 Lower coke rate, with consequent
RSP 410 2017-18 127 2017-18 430 108
BSL 467 2018-19 59 2018-19 479 63 increase in CDI rate, leads to reduction
ISP 384 2019-20 123 2018-19 402 112 in CO2 emission.
SAIL 2020-21 448 79
Plant-wise Best Coke rate in last 5 years and corresponding
Coke requirement for actual Hot Metal Production FY 2020-21

Best Achieved Hot Metal

Best achievement
  in last 5 years Production Total Coke (t)
Year
(Kg/thm) (2020-21)(t)

BSP 447 20-21 4,600,336 2,056,350

DSP 459 18-19 2,271,211 1,042,486
RSP 410 17-18 3,830,748 1,570,607
BSL 467 18-19 3,786,563 1,768,325
ISP 384 19-20 2,092,798 803,634

25
 Plant-wise Best CDI rate in last 5 years and corresponding CDI
Coal requirement for actual Hot Metal Production FY 2020-21

Best Achieved in last Hot Metal Total CDI Coal with

Best achievement
  5 years Production 5% Losses
Year
(Kg/thm) (2020-21)(t) (Tonnes)

BSP 76 20-21 4,600,336 367,107

DSP 57 18-19 2,271,211 135,932
RSP 127 17-18 3,830,748 510,830
BSL 59 18-19 3,786,563 234,578
ISP 123 18-19 2,092,798 270,285

26
Specific CO2 Emission for best achieved CDI & Coke Rate

Specific CO2 (t/tcs)

Crude Steel (2020- Specific CO2 (t/tcs)
 Plant With best CDI & Coke
21) (t) Actual (2020-21)
Rate
BSP 4,243,705 2.69 2.52
DSP 2,085,793 2.54 2.43
RSP 3,499,043 2.44 2.44
BSL 3,381,314 2.52 2.47
ISP 1,847,433 2.52 2.028
SAIL 15,057,288 2.55 2.42

27
Actionable points for Coke Rate reduction & CDI
Enhancement
▷ Increase in Hot Blast Temperature (HBT) to specified level
▷ Repair of hot blast stoves and/or provision of additional stove to maintain
uninterrupted supply of hot blast at desired temperature.
▷ Modern mushroom dome stoves and other modifications.
▷ Increased percentage of prepared burden in the blast furnaces.
▷ Uniform distribution of PCI with additional injection facility.
▷ Additional grinding facility for PCI coal for uninterrupted PCI injection.
▷ Provision of Shed in PCI coal yard.
▷ Interlinking of PCI coal Silos of Blast furnaces to ensure better availability of CDI
coal.
28
 Action Plan for Coke Rate & CDI
Plant Units Particular Target Timeframe Responsibility
GM (BF-O)/
BSL BF-1 to 4 Coke Rate (kg/thm) 420 2024-25
GM (BF/E&MOD)
GM (BF/Mech)/
BF-1 to 5 CDI (kg/thm) 90 2024-25
GM (BF/E&MOD)
402 Mar’22
RSP BFs Coke Rate (kg/thm) CGM (BF)
300-350 2030
135 Mar’22
CDI (kg/thm) CGM (BF)
180-200 2030
ISP BF-5 Coke Rate (kg/thm) 350 2023 HOD (BF)
CDI (kg/thm) 150/200 2023/2030 HOD (BF)
DSP BF-4 Installation of 4th Stove Coke Rate reduction = 6 kg/thm 2022-23 CGM (BF)/CGM (Proj)

Challenges:
▷ High gangue content in raw materials (iron ore/fluxes) leading to high coke rate.
▷ Smaller capacity BFs, with limitation of CDI enhancement.
▷ Non-availability pelletisation technologies. 29
Use of Energy efficient burners
 High efficiency Waste Heat Recovery
system - Utilizes waste heat of furnace
exhaust gas to pre-heat combustion air
using WHR regenerator situated at one
part of burner.
 Potential to reduces energy consumption
by 0.18 to 0.21 GJ/t-steel
 Saves 16-20 kg of CO2 per ton of product.
Status of Energy Efficient Burner Systems
▷ RSP: Digital burners installed in New Plate Mill and New Hot Strip Mill-2
▷ BSL: Reheating Furnaces in HSM equipped with Recuperative Burners.
Challenges:
▷ Min. 45 days shutdown requirement for installation of energy efficient
burners.
Scope for implementation of energy efficient burner systems:
▷ All the new Installations during the Phase-I expansion plan

31
Variable Voltage Variable Frequency (VVVF) drives

VVVF Drive employs frequency inverter technology which regulates

input voltage and frequency throughout the journey, drawing much less
current during acceleration and deceleration.
▷ Advantages of VVVF drives:
○ Depending upon application energy saving potential up to 88%.
○ Better control during acceleration /deceleration, avoid jerks.
○ Progressively installed in many units of SAIL
 Illustration of VVVF Drive Energy Saving Potential

(15 kW)
(50 kW) (50 kW)

(10 kW)
90 75

Mechanical Throttling Device versus a VFD

33
 Action plan for implementation of VVVF Drives/IE3 Motors
Plant Units/Inventory Targeted Energy Saving Potential Timeframe Responsibility
6300 (HT & LT Motors) 30557040 kWh (27501 t of CO2)
2000 LT Motors 15,66,75,739 kWh (1,41,008 t of HOD (Electrical) & HOD
BSP (IE1 to IE3) CO2) 2023-24
(Concerned shop)
2000 nos. of 1.5 T Conventional AC Units 103610 KWh (93.25 t of CO2)

SMS-I
66960 kWh HOD (SMS-I)
(2X120 kW)
SMS-I (45 kW) 4927.5 kWh HOD (SMS-I)
BSL 633600 kWh 2023-24
RMHP Wagon Tipler (08) HOD (RMHP)
(240 T)
460860 kWh
RMHP Belt Feeders (08) HOD (RMHP)
(270 T)
Already installed in old plate mill, new plate mill, HSM 1 & 2,. All new units under
RSP 2030 HOD (Proj.)
Vision 2030 planned with VVVF Drive
VVVF drives installed in some modex equipments,
CGM(Elect), CGM
DSP and in-house initiatives in primary and mill zone-40% completeda 2024
respective shops
Comprehensive plan for 100 % coverage in phases in all possible cases
ISP 90% VVVF Drive Coverage already achieved. New VFD in LDCP & BMP HOF (Elec) & HOD (Shop)
34
 Walking Beam type Reheating furnace (WBRH)
▷ Advantages of WBRH furnace along with DCS/ PLC system:
○ Reduces specific energy consumption upto 530 – 260 MCal/ T and
○ Scale loss limited to 0.6%.
▷ WBRH furnaces installed at most of the new mills of SAIL plants and some
existing mills like HSM of BSL.
 Action plan & Challenges for implementation of WBRH in
Mills

Plant Units Targeted Energy Saving Potential Timeframe Responsibility

BSP Rail & Structural Mill 0.406 Gcal/T (39788 T) 2023-24 HOD (RSM)
DSP 245 TPH Walking beam 26 months HOD (Proj.)
type reheating furnace for from Stage-II
proposed New Bar Mill

Challenges:
▷ Implementation schedule of walking beam furnace project is 22 months after
stage-2.
▷ Space and logistical constraints of existing set-up.

36
Switching over to Energy Efficient LED lights

▷ Advantages of LED lighting system:

○ Energy efficiency, enhanced life, less maintenance, cost saving and
improved carbon footprint.
○ 1 KWh energy savings reduces ~0.75 kg of CO2 emissions.
▷ > 1.75 lakh LED lights installed at plants and mines.
▷ Expected CO2 savings ~23,000 T per year (min. 50 watt savings in
each LED installation).
 Action plan for Complete Switch Over
Plant Conventional Plan for switching over and creation of Timeframe Responsibility
Lighting (Nos.) saving potential for Energy (kWh)/ CO 2
Emission (T)
BSP 282467 106,190,702 kWh / 95571.63 T 2022-23 HOD (Electrical)
BSL 223308 75,274,000 kWh / 28547 T 2022-23 HOD (Concerned
Shop)
DSP 11100 2,505,360 kWh (35% already achieved) Mar’23 PMD & Electrical
Plan for 100% switchover Coordination
RSP 100% coverage inside plant (85% already Dec’23 CGM(E)
achieved)
100% coverage in township (90% already Mar’23 CGM (TS)
achieved)
ISP 2646 MWh/24441 MWh already achieved. 2022-23 HOD (Elec.)
Plan for 100% switchover.

38
 Renewable Power - Generation and Consumption in SAIL
All figures are in MW and for Apr-Dec’21

Captive
Purchased from Power Total,
(Own Grid
Exchange (PX)  
Avg. Total +JV)
Power (X) (Y) (Z) (T =X +Y + Z)
Consumption
in SAIL 47.10
824.97 489.60 1361.67
(includes 23.0 MW RE)
Captive
RE Total RE RE Power Consumption
Installed Generatio Purchased Consumption as % of Total Power
RE Capacity n from PX   Consumption
Power (Solar)
(A) (B) C=A+B % of C/T
in SAIL

5.08 0.87 23.00 23.87 1.75 % 39

Use of Unconventional Energy
▷ CO2 emission saving potential of 1 MW Solar power Installation, with grid
emission factor of 0.91 = ~1300 T/yr.
▷ Solar installations may also help SAIL units to meet the REPO obligations
Thrust Areas:
○ Floating solar installation at water reservoirs of integrated steel plants, roof top solar
installation and other renewable sources
○ Possibility of installation of wind mill on cooling pond dyke being explored at BSL.
○ Huge water reservoirs present at SAIL plants
○ Vacant lands near Airstrips can be used for land based Solar Plants
Note: Presently India’s largest floating Solar plant at NTPC Simhadri (A.P.) – 25 MW in 100 acres (installed by BHEL).
600 MW floating Solar plant (1200 ha) on Omkareshwar Dam at cost of Rs. 30 billion – Expected by 2023.
105 MW floating solar power project at NTPC, Kayamkulam (Kerala) at cost of Rs. 3.43 billion – under implementation.
100 MW floating solar farm at NTPC Ramagundam in Telangana (450 acres) at cost of 4.32 bn – under implementation.
Source: https://www.power-technology.com/features/worlds-biggest-floating-solar-farms/
 Use of Unconventional Energy like Solar, Hydel & Wind

▷ Total power requirement at SAIL ~ year (1500 – 1700 MW/year).

▷ COP26 Target: 50% energy from Renewable Sources
Plants Capacity Type Status
BSP 0.2 MW Solar Rooftop Installed and in operation.
16 MW Floating Solar Expected completion by 2024
RSP 1MW Solar Ground Installed and in Operation
Mounted
5 MW Solar In Steel Township through M/S Crux Power , Bhubaneswar & Solar Energy Corp. of India
by March 2023.
10 MW Hydel Under implementation at Mandira Dam under Green Energy Development Corporation of
Odisha (GEDCOL).
BSL 84.6MW Floating Solar Proposal submitted by M/s MECON for installation 84.6MW floating solar power plant in
1.54 Km2 area of Cooling ponds. Estimated cost – Rs. ~348Crores.
ISP 4 MW Floating Solar Under tendering.
Other 2.045/ Rooftop Solar Installed and in Operation. Includes 1 MW at DSP. 1 MW under completion at ISP.
6.195 Discussion with vendors being done for remaining 4.10 MWp
 BOF gas recovery
BOF gas recovery at SAIL Plants during 2019-20:
 Plant BSP DSP# RSP BSL ISP
 BOF gas Recovery
 30.43  39 58 -   52.34 
(Nm3/tcs).
# Best achieved in DSP was 77.8 Nm3/tcs in 2016-17.

▷ CO2 emission saving potential of converter gas recovery is ~80 kg of CO2/tcs with
recovery potential of 100 Nm3/tcs.
▷ Estimate CO2 Emission savings of 2,93,360 tonnes can be achieved at BSL through
BOF gas recovery leading to specific CO2 emission reduction to 2.44 T/tcs from
2.52 T/tcs (2019-20)
▷ Efficient working of switching over station (flare stack to gas holder) with improved
software and automation may lead to better yield.
 Action Plan for Enhancing BOF Gas Recovery/Gas
Holders/Gas Fired Boilers
Plan for recovery
Plant Unit Timeframe Plan for Gas Holder/Gas Fired Boiler Responsibility
(Nm3/tcs)

SMS-II 55 Being Done Presently gas injected in CO gas line. CGM (SMS-I)
BSP
SMS-III 90 Mar’22 Installed. Commissioning by Feb’22 CGM (SMS-III)

SMS 80 Dec’22 Revamping of BOF Gas Holder to be taken-up CGM (SMS)

Coke Oven Dec’24 New 70,000 m3 COG Holder CGM (CO)
DSP
100 TPH Gas Fired Boiler (Under Tendering. 22 months
Power Plant HOD (Proj.)
from Stage-2)
Gas holder under maintenance. Expected to be online by
SMS-2 80-90 March 2022 HOD (SMS-2)
Jan’22.
RSP
HOD (SMS-
SMS-3 80-90 2025-26
Proj.)

BSL SMS-2 50 Mar’22 Gas holder Installed. Under commissioning --

SMS-1 Not yet planned Jun’22 CGM (SMS-1)

ISP SMS 80-90 2022-23 Gas holder already installed and in operation. CGM (Steel)
43
 100% Online Metering & Monitoring of All Forms of Energy

▷ RSP & ISP – Centralised energy monitoring system installed & in operation.

▷ BSP & BSL- Monitoring of gaseous fuel being done. Partial coverage for steam.

▷ DSP – Old system of metering & record keeping present.

Action Plan:

○ Achieve 100% coverage at BSP & BSL.

○ DSP may expedite integrated monitoring system for energy

○ Bring uniformity of data metering and record keeping across all SAIL units.
 Circular Economy – Waste Management through Reduce,
Reuse, Recycle & Remanufacture
Plant-wise Solid wastes utilization (%) during 2020-21:

  BSP DSP RSP BSL ISP SAIL

BF Slag 93.56 102.25 101.94 100.06 99.54 98.99

BOF Slag 48 75 42 106 50 62

▷ Using of BOF slag in cement making and as liming agent in agriculture saves CO2 emission of
~0.3 and 0.42 ton per ton of BOF slag used, respectively.
▷ Possibility to use 10-15% BOF slag in cement feed mix being ascertained through R&D efforts.
▷ R&D to ascertain use of BOF slag as liming agent for amelioration of acidic soil being done
through ICAR-IARI by MoS and industry partners SAIL, JSW & Tata steel.
▷ Proposal put up by West Bengal State Rural Department Agency to Ministry of Rural
Development for use of BOF slag in village Roads under PMGSY. Expected shortly.
 Circular Economy – Waste Management through Reduce,
Reuse, Recycle & Remanufacture
▷ Facilities needs to be created for utilising ~ 0.73 MT BOF slag.
▷ Potential of additional CO2 emissions reductions from 0.22 to 0.31 MTPA can be
created for use in cement making/agriculture.
▷ Crushing to desired size and metal recovery necessary for use of BOF slag in Cement
Making and agriculture.
Action plan:
○ Possibility to use of BOF slag for bandh restoration in low lying areas of South Bengal,
through state agencies.
○ Briquetting/micro-pelletisation of BF/BOF sludge.
Plant Plan Timeframe Responsibility
DSP Installation of Micro-pelleting plant for reuse of all recyclable wastes Mar’24
All plants Facilities for crushing & size wise segregation of BOF slag after metal 2023-24 HOD (SMS) & HOD (MRD)
recovery.
 Enhancement in Scrap Use in Steelmaking
▷ Scrap plays a vital role in reducing the Carbon input to Iron & Steel making
process.
▷ During 2020-21, around 86kg of home scrap is used in SAIL to produce 1 tonne
of steel (~9%).
▷ National Steel Policy 2017 for Scrap Use in Charge mix of BOF : 15%
▷ Every tonne of scrap used for steel production avoids the emission of 1.5 tonnes
of CO2 and consumption of 1.4 tonnes of iron ore, 740kg of coal and 120 kg of
limestone. (Source: worldsteel)
▷ Every 1% increase of scrap use in steel making at SAIL creates potential to reduce
CO2 emission by 0.76 MT.

Plant Plan for scrap utilisation Timeframe Responsibility

All plants Enahnce scrap use in steel making to 15% 2028-29 HOD (SMS)
47
 Use Pellets in BF Charge
▷ As per NSP 2017, Charge mix in BF considered to be 60% Sinter, 25% Pellet & 15%
Lump ore.
▷ CO2 Emission factor for pellet production is 0.015 to 0.032 t/t of pellet to 0.4 to 0.7
t/t of sinter production.
▷ Dust, SO2, NOx, CO & PAH emissions are also lower in pellet production.
▷ Use of pellets results in lower slag rate & coke rate and higher BF Productivity in the
blast furnaces leading to lower carbon footprint.

48
 Implementation of Pelletizing Facilities at SAIL
▷ Scope for reduction of CO2 Emissions of 3.25 million tonnes every year using 25%
Pellet and 60% Sinter in BF charge.

Plant / Unit Capacity Responsibility Present Status

(Implementation strategy)
BSP / Dalli 1 MTPA HOD (Proj, BSP- Foundation stone laid on 14/06/2021.
Mechanised Mines (BOO) Mines) Under tendering (TOD – 31/01/2022).
Pre-bid conference – 13/01/2022.
Completion – 24 months from effective date of contract.

RSP 2 MTPA HOD (Projects) Stage-I approval received. Proceeding for tendering.
(COM) Completion – 24 months from effective date of contract.

BSL / Gua Ore 4 MTPA HOD (GOM) Under stage-1 approval.

Mines (MDO) Completion – 36 months from stage-II.

BOO: Built Own & Operate; COM: Construct Operate & Maintain; MDO: Mine Developer & Operator
49
 Phase-1 Expansion Plan as per Vision 2030.

Envisaged Crude Steel Capacity Tentative additional capacities being

Plant
in MEP (MTPA) planned in Phase-I (MTPA)

Bhilai Steel Plant 7.0$ Nil

Durgapur Steel Plant 2.5^ 1.5 – 2.0
Rourkela Steel Plant 4.850* 4.5 – 5.0

Bokaro Steel Plant 4.66^ 4.5 – 5.0

IISCO Steel Plant 2.5 3.0 – 5.0

$ BSP capacity to be achieved after installation of 4 th caster in SMS-III; No capacity addition in phase-I expansion.
^ After ongoing EC expansion for DSP and BSL.
* RSP capacity to be achieved after installation of 4 th caster in SMS-2 and ongoing EC projects, viz. COB #7, new SMS-3
(phasing out of SMS-1), enhancement in hot metal production, among others.
50
Technology Landscaping of Vision 2030 for higher Efficiency &
lower CO2 Footprint
▷ Coke Dry Cooling Plants for stamp charge Coke Ovens of 1 MTPA capacity
▷ Higher volume Blast Furnaces with TRT of 5580 m3 (except ISP – 4160 m3),
with WHR from stoves and Torpedo ladles for hot metal transport
▷ WHR from Sinter Coolers
▷ BOF Gas recovery from all converters.
▷ Alternative routes of Iron making like Midrex/Finex as a long term measure as
scrap balance for BOF/ EAF.
▷ Introduction of Thin Slab Casting & Direct Rolling at BSP, DSP, BSL and ISP
(Kulti)
▷ Energy efficient reheating furnaces, burner systems
51
 SAIL Vision 2030: Techno-Economic Parameters

  Unit Existing BFs New BF Overall

(less than 4000 m ) (4000 m3 and above)
3

BF Productivity t/m3/day 2.0 2.75 2.54

Coke Rate kg/thm 420 310 340
CDI kg/thm 100 200 173
Nut Coke kg/thm 20 20 20
Fuel Rate kg/thm 540 530 533
5.5
Sp. Energy Consumption GCal/tcs    
(current 6.5)
Sp. Water Consumption Cu.M/tcs     2.75 
(current 3.57)

52
 Tentative Timeline for Implementation of Phase-I Expansion
Plan

Particular Timeline Responsibility

Finalisation of Product Mix, Technology & Config May 2022 Business Planning/CMO

Pre-feasibility Report Jul 2022 CET/Plants

In-principal Clearance of SAIL Board Sep 2022 Project/Plants
DPR Apr 2023 Plant/CET
Final EC (Process to start after Pre-FR Jun 2023 Plant/EMD
Preparation)
Stage-I Approval Aug 2023 Projects/Plant
Appointment of PMC & Engg. Consultant Aug 2023 Projects/Plant
Stage-II Approval Dec 2023 Plants
Implementation of Phase-I Expansion Plan 2028-29 Plants

53
CO2 Emission Reduction with Present Trends
Specific CO2 Emission Trends (BAU) vis-à-vis 2030 Target

2.61
2.6 2.56 2.57
2.54 2.55

2.5
2.41
2.4

2.3 2.3

2.2
16-17 17-18 18-19 19-20 20-21 21-22 22-23 23-24 24-25 25-26 26-27 27-28 28-29 29-30

Note: Linear trend lines obtained using MS excel software based on reduction trends for last 5 years

 Target for reducing specific CO2 Emission by 2030 – 2.30 T/tcs

 Projected Specific CO2 emission by 2029-30 considering business as usual (BAU)
reduction trends - 2.41 T/tcs 54
VISION 2030 – A Game Changer for reducing Carbon Footprint

Projected Crude Steel Production vis-a-vis Sp. CO2 Emission

Crude Steel Prodcution (MTPA)

2.6 60
2.55 2.53
50
Sp. CO2 Emission (T/tcs)

2.48
2.5 2.42
50

2.4 35.8 40

2.3 30
2.29
2.2 2.25 20
19.36 21.51
16.81
2.1 15.02 10

2 0

Specific CO2 Emission (T/tcs) Crude Steel Production (MTPA)

55
 Phase-3
Deep Decarbonisation
Moving Towards Carbon Neutrality

56
SAIL journey towards carbon neutrality starts post 2030 period

57
Need for Breakthrough Steel Making Technologies

▷ Till now focus was on material management, energy efficiency and carbon
emission reduction.
▷ Existing clean technologies helpful for carbon abatement and not enough to
attain carbon neutrality.
▷ Hydrogen can replace the fossil fuels required to reach high temperatures, as
well as the carbon used in the reduction of iron ore.
▷ Use of Green Hydrogen in steel making, along with electricity from
renewable sources, guarantees complete decarbonization.

58
“Hydrogen – Fuel of the Future”

59
Responsibility Matrix – Deep Decarbonisation

BREAK THROUGH GREEN ENERGY

TECHNOLOGIES

CARBON NEUTRALITY

TRANSITION-
INTERNAL CARBON CONVENTIONAL TO NEW
PRICING ARCHITECTURE

60
 Technology Missions (TM) for Achieving Carbon
Neutrality

Setting-up Internal Carbon Pricing for SAIL 2022 EMD/Plants

TM-1
Assessment of CCUS/Breakthrough Technologies for
2025 EMD/RDCIS/Plant
adoption at SAIL Plants

Development of Pilot/Demonstration Plant for

CCUS/Breakthrough Steel Making Technology within
TM-2 existing plant in association with academia and 2030 EMD/RDCIS/Plant
technology provider, rate the commercial success of
new technologies across the globe

Transition to Carbon Neutrality – CONVENTIONAL TO

TM-3 NEW ARCHITECTURE – funding-socio economic conflict- Post 2030 EMD/CET/Plants

61
Hydrogen Steel Making – Major Units
Hydrogen Alkaline electrolyser (AE) produce
Production And hydrogen and oxygen from fresh
Storage System & recycled water

Iron and Steel

In Shaft furnace hydrogen reacts iron
Production Unit ore to produce DRI and
hydrogen/steam mixture

Renewable energy
Hybrid Renewable storage- Intermittency of
electricity from solar and wind power
solar and wind
energy to meet Proton Exchange
power requirement Membrane Fuel
Cell(PEMFC) 62
 Technologies to produce Steel using Hydrogen expected to be
available post 2030

Developer Technology Remarks

JV of Swedish companies SSAB, Hydrogen Breakthrough Ironmaking Commercially available by
Luossavaara-Kiirunavaara Technology (HYBRIT) for 100 per 2035
Aktiebolag (LKAB), and Vattenfall cent fossil-free steelmaking
Voestalpine, in partnership with H2-DRI with 6 MW of electrolyser Reduce emissions by 30% by
Siemens and VERBUND capacity 2035 and over 80% by 2050.

Celsa, Norway in association with Hydrogen production through 40-50 Electrolyser project expected
Nel Hydrogen Electrolyser and MW of alkaline electrolysers to be operational by 2023.
Statkraft
HBIS Group (China) in association 600,000 Tpa H2-DRI plant using Carbon footprint= 250 kg of
with Tenova ENERGIRON technology CO2/T of DRI

ArcelorMittal (Sestao plant, Spain) 1.6 MTPA H2-DRI plant To be operational by 2025.
63
 Status of Low and Ultra Low CO2 Emission Technologies in
Steel Industry
Steel Companies Process of Low carbon steel Status
Aço Verde do Brasil Charcoal to produce low carbon iron and steel products. In operation.
Capacity of 0.6 MT per year.
In 2020, achieved -0.04 mt of CO2
per ton of steel.
ArcelorMittal Blast Furnaces gas to ethanol based on LanzaTech Expected by 2022
Technology.

Geological CO2 sequestration from steel works in Belgium

and France by shipping to Norway.

Shougang Steel in China Waste gas to ethanol based on LanzaTech Technology. In operation since 2018

Emirates Steel in the United ~800kt of CO2 per year sequestered into a mature oil field for In operation
Arab Emirates permanent storage using Amine Solvent based Absorption/
Regeneration System
EVRAZ’s Rocky Mountain Steel Use of solar energy for steel production Solar plant came online in
in Colorado Oct’21.
64
 Status of Low and Ultra Low CO2 Emission Technologies in
Steel Industry
Steel Companies Process of Low carbon steel Status
HBIS, a leading Chinese 1.2Mt capacity hydrogen metallurgy DRI demonstration In pipeline
steelmaker project. The project will use green and blue hydrogen
technologies. 
Nucor’s micro mill in First U.S. steel plant to run on wind energy. In pipeline
Sedalia, Missouri
Tata Steel HIsarna technology for producing iron without coke ovens, or Under development.
agglomeration facilities
The fifth pilot campaign was
The raw materials shall be used in powder form and directly successfully concluded in 2019.
converted into liquid pig iron.
Thuyssenkrupp Use of hydrogen in working blast furnace at Duisburg- In pipeline
Steel and Nippon Steel Hamborn by 2022 .
Corporation
Further 0.4 MTPA green hydrogen-based steel plant by 2025.
Carbon2 chemical – Steel plant waste gases as a raw material for producing First project phase at
Thyssen krupp chemicals such as ammonia and methanol. thyssenkrupp’s Duisburg steel mill
demonstrates technical feasibility
Use of Renewable energies to generate the additional and confirms commercial viability.
hydrogen
65
 NEED FOR
CCUS
PHASE-I

PHASE-III PHASE-
II

CCUS NET
ZERO

66
“CCUS crucial for Net Zero Emissions”

67
Carbon Sequestration
▷ Carbon Sequestration is type of Carbon Capture and Storage that
removes carbon from point source/ atmosphere and deposits it in a
reservoir.
▷ Type of Sequestration:
• Terrestrial or Biological sequestration,
• Geological sequestration,
• Ocean sequestration, and
• Chemical sequestration.

68
Carbon Sequestration Types

69
CCUS Potential of Steel Industry
▷ Multiple flue stacks act as point sources of CO 2.

▷ 85% of carbon (CO2 plus CO) introduced into the iron and steel making
process is present 69% in the BFG, 9% in COG, and 7% in BOF gas.
▷ Flue gas streams from BF and CPP, streams with highest CO 2 volume, techno-
economically attractive sources for CO2 capture.
▷ CCS project of Emirates steel (Abu Dhabi) – World’s 1st large scale CCS
project in steel industry, in operation since 2016.
○ 0.8 Mt/y of CO2 is captured from the Coal based HYL-DRI process.
○ CO2 is captures using Amine absorber and regenerated using Desorber.
○ Captured CO2 transported in 43 km pipeline to the Rumaitha oil field for 70
 CCUS for Enhanced Coal Bed Methane (ECBM) Recovery using
CO2 injection

▷ ECBM involves CO2/N2 injection into coal to

improve methane recovery, analogous to
enhanced oil recovery (EOR).
▷ Captured CO2 from industry is transported
to site and injected into cleats.
▷ Due to high adsorptivity, CO2 preferentially
adsorbed into coal matrix.
○ Methane displaced from sorption sites.
▷ Efficient displacement process – slow CO2
breakthrough
Source: https://www.mdpi.com/energies/energies-11-02996/article_deploy/html/images/energies-11-02996-g001.png 71
 ECBM potential nearby SAIL plants
Recoverable CBM Reserve (Billion
State Block/Dist Operator
Cu. M)
West Bengal Raniganj Essar Oil Ltd 3.2
Raniganj North ONGC 14
Raniganj South GEECL 37.94
Jharkhand Bokaro ONGC 3.68

DSP ( million Nm3) ISP ( million Nm3) SAIL 2 plants (million Nm3)
Pre-combustion CO2 capture potential
606.04 651.33 1,257.37
from by-product gases
Post-combustion CO2 capture potential
2949.74 3760.70 6710.44
from Point Sources (Stacks)

Considering vol % of flue gas streams, highest concentration of CO 2 is in the stacks of Calcination plant (30%) followed by COB & BF
(25% each) and Power plant (20%).
72
Thank You

73